Improved thickness measurement on rough surfaces by using guided wave cut-off frequency

Substantial variability is seen when thickness measurements using conventional ultrasonic time of flight measurements are carried out on rough surfaces; this makes it difficult to estimate corrosion rates when the corrosion mechanism leads to surface roughness. It has been shown that thickness measurements using guided wave cut-off frequencies (through thickness resonance frequencies) can be done at much lower frequencies than conventional time of flight thickness gauging for the same minimum thickness resolution. The lower frequency measurements are less susceptible to variations caused by surface roughness and so will give more consistent and reliable results in cases where corrosion leads to increased surface roughness. Measurements were carried out using guided wave cut-off frequencies on four plates with different surface roughness. On a plate with root mean square (rms) surface roughness of 0.3 mm, the thickness estimates followed the trend predicted from the plate geometry and probe footprint, whereas higher frequency measurements reported in the literature deviated from this trend at an rms roughness of 0.1 mm. The guided wave cut-offcut-off frequency measurements can be done using the same transduction system as that used for large area guided wave monitoring so it is possible to combine large and small area monitoring in a single unit. Frequent measurements enable the wall thickness obtained with guided wave cut-off measurements to be tracked with time, and the low susceptibility of the measurements to surface roughness means that accurate corrosion rates will be obtained.